Estimation of Cutting Force Coefficients for Flat End Mills by Measuring of Surface Error

In this paper¡ a new approach for calculation of the cutting force coefficients which are the most important and significant factor in prediction of machining forces¡ is presented for flat end mills. The proposed methodology models a practical mechanism for collecting and analyzing experimental data. The surface error is the measured parameter used for defining the cutting-force coefficients. Neglecting the effects of other factors that cause to deflect cutting tools¡ in cutting process¡ the machining forces imposed on flat end mills are considered as the most important factor in deflection of machining tool that leading surface error. In this research¡ The Ving-Lee model which is an appropriate force model with a good ability on milling process mechanical modeling is used. In proposed method¡ the related cutting force coefficients of the force model are calculated by measuring the surface error on a profile of the machined surface along End Mill that caused by tool deflection under machining forces¡ and by correlate error along this profile to tool deflection and use of equation between tool deflection and cutting force. The resulted forces and surface error¡ when applying the new cutting force coefficients show a good agreement between the predicted and measured.